Method for manufacturing a layer lamination integrated fuel cell and the fuel cell itself

ABSTRACT

The present invention provides a method for manufacturing a layer lamination integrated fuel cell. A membrane electrode assembly layer has at least one fuel cell unit. The anode current collection circuitries are formed on a single surface, which contacts anodes of all the fuel cell units, of the first printed circuit substrate. The cathode current collection circuitries are formed on a single surface, which contacts cathodes of all the fuel cell units, of the second printed circuit substrate. The membrane electrode assembly layer can be tightly placed in between the first printed circuit substrate and the second printed circuit substrate to be a sandwich structure.

FIELD OF THE INVENTION

The present invention relates to a method for manufacturing a layer lamination integrated fuel cell, especially to the method for manufacturing a current collection layer of the fuel cell. That is, to separately produce anode current collection circuitries and cathode current collection circuitries on each single surface of printed circuit substrates.

BACKGROUND OF THE INVENTION

The manufacturing methods for the fuel cell in the prior arts are all mainly related to the whole structure of the fuel cell or the technical field of the membrane electrode assembly layer; for the manufacturing method or the structure of the current collection layer is disclosed utilizing graphite, metallic mesh, etc. only. Although the means do manufacture the current collection layer and have functions thereof, the prior arts are still restricted by some conditions for making a small and light cell.

SUMMARY OF THE INVENTION

The primary objective of the present invention is to provide a process for manufacturing a layer lamination integrated fuel cell, which is manufactured by producing individually anode current collection circuitries and cathode current collection circuitries on each single surface of printed circuit substrates by way of the PCB(Printed Circuit Board) process. The second objective of the present invention is to provide a current collection layer for the use of a small, light fuel cell.

To approach the above objectives, the present invention provides the method for manufacturing a layer lamination integrated fuel cell comprising: (a) providing a membrane electrode assembly layer having at least one fuel cell unit; (b) forming anode current collection circuitries on a single surface, which contacts anodes of all the fuel cell units, of a first printed circuit substrate by way of the PCB process; (c) forming cathode current collection circuitries on a single surface, which contacts cathodes of all the fuel cell units, of a second printed circuit substrate by way of the said PCB process; (d) tightly placing the membrane electrode assembly layer in between the first printed circuit substrate of completing the step (b) and the second printed circuit substrate of completing the step (c) to be as a sandwich structure.

To achieve the above objectives, the present invention provides a layer lamination integrated fuel cell comprising: a membrane electrode assembly electrode layer having at least one fuel cell unit; a first printed circuit substrate having anode current collection circuitries, wherein the anode current collection circuitries are formed on a single surface, which contacts anodes of all the fuel cell units, of the first printed circuit substrate; a second printed circuit substrate having cathode current collection circuitries, wherein the cathode current collection circuitries are formed on a single surface, which contacts cathodes of all the fuel cell units, of the second printed circuit substrate; wherein the membrane electrode assembly layer can be tightly placed in between the first printed circuit substrate and the second printed circuit substrate to be like a sandwich structure.

BRIEF DESCRIPTION OF THE DRAWINGS

The above objects and advantages of the present invention will become more apparent with reference to the appended drawings wherein:

FIG. 1 is a flow chart of the present invention;

FIG. 2 is an exploded diagram of a layer lamination integrated fuel cell manufactured by the method of the present invention;

FIG. 3 represents a first printed circuit substrate with anode current collection circuitries and serial and parallel circuits of the present invention;

FIG. 4 represents a second printed circuit substrate with cathode current collection circuitries and serial and parallel circuits of the present invention; and

FIG. 5 represents a structure of combining a fuel flow layer and the layer lamination integrated fuel cell of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Please refer to FIG. 1, which is a flow chart of the present invention; and FIG. 2, which is an exploded diagram of a layer lamination integrated fuel cell manufactured by the method of the present invention. Method 10 for manufacturing the layer lamination integrated fuel cell comprises: step (101): providing a membrane electrode assembly layer 23, that is, the layer 23 is made to coat platinum with the predetermined concentration and platinum/ruthenium with the predetermined concentration on the proton exchange membrane and macromolecule material, and to combine a proton exchange membrane, macromolecule catalytic layer and carbon paper by way of lamination. The material of the proton exchange membrane can be DuPont Nafion, the method of coating adopts Polyimide Printing. For example, the predetermined concentration of 1˜5 mg/cm2 of platinum and the predetermined concentration of 1˜10 mg/cm2 of platinum/ruthenium can be manufactured by means of metallic vacuum vapor deposition, continuously to print some mixtures of carbon, Teflon, solvent, etc. by way of halftone printing or flat printing to form the layer 23, which is a membrane electrode assembly layer. The layer 23 comprises a plurality of fuel cell units 23 a, please refer to FIG. 2.

Step (103) is to form anode current collection circuitries 211 on a single surface, which contacts the anodes of all the fuel cell units 23 a, of a first printed circuit substrate 21 by way of the PCB process. Referring to FIG. 2, the single surface of the first printed circuit substrate 21 is the surface for touching with the anode of each fuel cell unit 23 a; another surface relative to the surface for touching the anode is not a key part of the method 10. In the step (103), it is forming anode current collection circuitries 211 on a single surface of a first printed circuit substrate 21 by way of the PCB process. The preferred embodiment is to drill a plurality of holes 217 on the area distributed over the circuitries 211, and the holes 217 function to let anode fuel pass through, and the anode fuel can then be in the fuel cell units 23 a. Constantly, to form conductive material as conduction glue, conduction band, metallic lamination, etc. on the first printed circuit substrate 21 via coating, printing, adhering, electroplating build-up, etc., or to adopt the process of etching metal of the substrate 21 to produce the circuitries 211. The metal can be copper or other types of metallic material. The present invention having the way of forming anode current collection circuitries 211 on the single surface of the first printed circuit substrate 21 may not be a restriction; any other technical field belonging to the spirit of the present invention shall be in the scope of the present invention.

Step (105) is to form cathode current collection circuitries 251 on a single surface, which contacts the cathodes of all the fuel cell units 23 a, of a second printed circuit substrate 25 by way of said PCB process. In FIG. 2, the single surface of the first printed circuit substrate 25 is the surface for touching the cathode of each fuel cell unit 23 a; another surface relative to the surface for touching with the cathode is not a key part of the method 10. In step (105), the cathode current collection circuitries 251 are able to be made by way of the method in step (103). Same theory, holes 257 are to let the air pass through, and the air will then be in fuel cell units 23 a.

In the step (107): it is that tightly placing the membrane electrode assembly layer 23 in between the first printed circuit substrate 21 of completing the step (103) and the second printed circuit substrate 25 of completing the step (105) to be as a sandwich structure of a layer lamination integrated fuel cell 20. To laminate the sandwich structure in step (107) it may adopt epoxy, the stacking methods of printing or glue pieces and the laminating method of a thermocompressor to tightly combine together.

While proceeding to step (103), a further step to form serial and parallel circuits 213 can be engaged, that is, the serial and parallel circuits 213 can be manufactured on the single surface of the first printed substrate 21 via the PCB process. Since the serial and parallel circuits 213 electrically connecting to the anode current collection circuitries 211, the anodes of the fuel cell units 23 a can then be in the connection of serial and parallel from the design of the serial and parallel circuits 213. All other corresponding serial and parallel circuits 213 may be connected as well, and therefore necessary provided voltage for each of fuel cell unit 23 a is made successfully.

While proceeding to step (105), a further step to form serial and parallel circuits 253 can be engaged, that is, the serial and parallel circuits 253 can be manufactured on the single surface of the second printed substrate 25 via the PCB process. Since the serial and parallel circuits 253 electrically connecting to the anode current collection circuitries 251, the cathodes of the fuel cell units 23 a can then be in the connection of serial and parallel from the design of the serial and parallel circuits 253. All other corresponding serial and parallel circuits 253 may be connected as well, and therefore necessary provided voltage for each of fuel cell unit 23 a is made successfully.

After manufacturing the anode current collection circuitries 211, the serial and parallel circuits 213, the cathode current collection circuitries 251 and the serial and parallel circuits 253, an isolating layer 215 and another isolating layer 255 are individually formed on the first printed circuits 21 and the second printed circuits 25. Outside the anode current collection circuitries 211 and the cathode current collection circuitries 251 may be isolated by means of the two isolating layers 215, 255 so as to connect the circuitries 211 and the circuitries 215 to each fuel cell unit 23 a only. The preferred embodiment for the isolating layers 215, 255 may coat soldermask paint.

FIG. 3 represents the first printed circuit substrate with the anode current collection circuitries and the serial and parallel circuits of the present invention, and FIG. 4 represents the second printed circuit substrate with the cathode current collection circuitries and the serial and parallel circuits of the present invention. The first printed circuit substrate 21 and the second circuit substrate 25 can be chosen from one of the following: copper clad laminate, flexible printed circuit board, substrate for the PCB process. Further, the printed circuit substrates in FIGS. 3 and 4 can be produced separately, and then to combine with the membrane electrode assembly layer 23 as a sandwich structure.

FIG. 5 represents a structure of combining a fuel flow layer and the layer lamination integrated fuel cell. The manufactured fuel cell 20 is to combine with the fuel flow layer 30, and an internal room 30 a of the fuel flow layer 30 is to be reserved for anode fuel as a methanol solution. The internal room 30 a connects to the holes 217 of the anode current collection circuitries 211 as well, and it is for anode fuel going to each fuel cell unit 23 a.

A preferred embodiment of aforesaid fuel cell 20 is a layer lamination integrated direct methanol fuel cell.

While the invention has been described by way of example and in terms of a preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures. 

1. A method for manufacturing a layer lamination integrated fuel cell comprising: (a) providing a membrane electrode assembly layer having at least one fuel cell unit; (b) forming anode current collection circuitries on a single surface of a first printed circuit substrate by way of PCB process, wherein the surface of the first printed circuit substrate is contacted with anodes of all the fuel cell units; (c) forming cathode collecting circuits on a single surface of a second printed circuit substrate of by way of said PCB process, wherein the surface of the second printed circuit substrate is contacted with cathodes of all the fuel cell units; and (d) tightly placing the membrane electrode assembly layer in between the first printed circuit substrate of completing the step (b) and the second printed circuit substrate of completing the step (c) to be a sandwich structure.
 2. The method for manufacturing a layer lamination integrated fuel cell of claim 1, wherein the step (b) further comprises the following step: forming serial and parallel circuits on the single surface with the anode current collection circuitries, wherein the serial and parallel circuits being electrically connected to the anode current collection circuitries.
 3. The method for manufacturing a layer lamination integrated fuel cell of claim 1, wherein the step (c) further comprises the following step: forming serial and parallel circuits on the single surface with the cathode current collection circuitries, wherein the serial and parallel circuits being electrically connected to the cathode current collection circuitries.
 4. The method for manufacturing a layer lamination integrated fuel cell of claim 1, wherein the first printed circuit substrate can be one of the following: copper clad laminate, flexible printed circuit board, substrate for the PCB process.
 5. The method for manufacturing a layer lamination integrated fuel cell of claim 1, wherein the second printed circuit substrate can be one of the following: copper clad laminate, flexible printed circuit board, substrate for the PCB process.
 6. The method for manufacturing a layer lamination integrated fuel cell of claim 1, wherein the layer lamination integrated fuel cell is a layer lamination integrated direct methanol fuel cell.
 7. A layer lamination integrated fuel cell comprising: a membrane electrode assembly layer having at least one fuel cell unit; a first printed circuit substrate having anode current collection circuitries, wherein the anode current collection circuitries are formed on a single surface of the first printed circuit substrate, and wherein the surface of the first printed circuit substrate is contacted with anodes of all the fuel cell units; a second printed circuit substrate having cathode current collection circuitries, wherein the cathode current collection circuitries are formed on a single surface of the second printed circuit substrate, and wherein the surface of the second printed circuit substrate is contacted with cathodes of all the fuel cell units; wherein the membrane electrode assembly layer can be tightly placed in between the first printed circuit substrate and the second printed circuit substrate to be as a sandwich structure.
 8. The layer lamination integrated fuel cell of claim 7, wherein the first printed circuit substrate further comprises: serial and parallel circuits electrically connecting to the anode current collection circuitries are formed on the single surface with the anode current collection circuitries.
 9. The layer lamination integrated fuel cell of claim 7, wherein the second printed circuit substrate further comprises: serial and parallel circuits electrically connecting to the cathode current collection circuitries are formed on the single surface with the cathode current collection circuitries.
 10. The layer lamination integrated fuel cell of claim 7, wherein the first printed circuit substrate can be one of the following: copper clad laminate, flexible printed circuit board, substrate for the PCB process.
 11. The layer lamination integrated fuel cell of claim 7, wherein the second printed circuit substrate can be one of the following: copper clad laminate, flexible printed circuit board, substrate for the PCB process.
 12. The layer lamination integrated fuel cell of claim 7, wherein the layer lamination integrated fuel cell is a layer lamination integrated direct methanol fuel cell. 